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Calculation Example - Creep Assessment: Help For Engfit Toolbox™
Calculation Example - Creep Assessment: Help For Engfit Toolbox™
The furnace tubes are known to have been in service for approximately 8 years:
For a creep design life of 100,000 hours, this furnace has used ~70% of its life. However,
the tubes are subject to a metal thinning rate (MTR) of 0.15mm/yr from, for example,
combined internal corrosion and external oxidation.
This assessment module makes use of the Life Fraction Rules (LFR). The operation of
the furnace is divided into periods of time in which the pressure, metal temperature, and
corrosion rate are assumed constant.
For each of these periods, the creep life fraction consumed is calculated. The sum of
these fractions for each period, is the total accumulated creep damage.
The tube internal pressure hoop stress (S) for each period, calculated from accumulated
metal loss due to thinning at the end of the period is used, which is considered to
provide sufficient conservatism, as follows:
The minimum Larson-Miller Parameters (LMPmin) are determined from the pressure
hoop stress (S) using the curves in API RP 530, as follows:
In this example, refer to Figure 3O (SI) – Types 347. In an actual heater, neither the
operating pressure nor the metal temperature is uniform.
Period # =1
Duration (increment) = 1.3years x 365.25days x 24hours = 11,396 hours
Operating pressure (Po) = 3.96MPa
Metal temperature (To) = 649°C
Initial thickness (ti) = 6.8mm
Thickness, end of period (te) = 6.8 – (1.3 x 0.15) = 6.61mm
Stress (S) = (3.96/2)((168.3/6.61)–1) = 48.5MPa (7.03ksi)
LMPmin = 34.36 (US units)
logLr = 10[(LMPx1000)/(To+460)-15] (US units)
Lr = 494,957 hours
Life fraction (minimum) = 11,396 / 494,957 = 0.023
The life fractions are the increment period (11,396 hours) divided by the rupture time
that corresponds to that period.
At each calculation increment, the strength of tube should also be checked for failure by
plastic collapse. This will occur if the tube stress (which is continually increasing due to
corrosion) is equal to the allowable elastic strength (Se) at the specified operating
temperature.
Se is equal to two-thirds of the specified minimum yield strength (SMYS, σy) of the tube
material at design temperature (T).
The calculation of SMYS for 18Cr-10Ni-Cb (Type 347 stainless steel) is based on Table
F.3 in API RP579, as follows:
σry is the yield strength (ie. 24.1ksi) at the temperature of 400°F (for TP347SS). In this
particular example (after substituting values for Ai and T in the above formula), if T =
700°C then σy = 18.49ksi (127.45MPa). Se is therefore equal to 85.0MPa. The minimum
allowable thickness (temin) at a design temperature of 700°C and at a design pressure of
4MPa is calculated as in API RP530. temin is equal to 3.87mm.
These failure criteria are highlighted in red in the following table. The remaining life is
then simply calculated as the cumulative period (148,148 hours) at which any of these
two criteria are first reached, minus the operating life (70,128 hours). This is equal to
78,020 hours.
Note: Question 2 and Question 3 in this example is best answered using the
sensitivity calculator in Creep Module in ENGFit Toolbox.